Transmission
Note. There are 2 Light Duty truck emission control standards classifications: Light Duty and Heavy Duty. Light Duty refers to vehicles up to 8500 lbs. (GVW); Heavy Duty refers to vehicles over 8500 lbs. (GVW).
On "S" models with 4-speed transmission, change transmission fluid after the first 7500 miles and at 30,000 mile intervals thereafter. On all other Light Duty vehicles, check transmission fluid every 12 months or 7500 miles. On Heavy Duty vehicles, check fluid level every 12 months or 6000 miles. Periodic draining and refilling is not required.
Transfer Case
Check transfer case lubricant at every oil change or every 12 months. Under severe conditions check more frequently.
Check lubricant level at transmission filler plug hole. Lubricant should be level with bottom of hole. Add as needed.
Remove filler plug. Check oil level. If level is not up to filler plug opening, add lubricant until it is.
The 77mm 5-speed and 89mm 4-speed overdrive use Dexron II ATF. The 117mm 4-speed uses API GL5 SAE 80W90 gear lubricant. General Motors recommends the use of Manual Transmission Fluid 1052931 in the 85mm 4-speed and 85mm 5-speeds.
Transfer cases use DEXRON-II ATF.
FLUID CAPACITY
Note. Capacities listed in the following chart are approximations only. Correct fluid level should be determined by level at filler plug hole, rather than by amount added.
| Application | Quantity |
|---|---|
| 5-Speed (77mm) | 3.2 pts. (1.5L) |
| 4-Speed (85mm) | 3.6 pts. (1.7L) |
| 5-Speed (85mm) | 3.6 pts. (1.7L) |
| 4-Speed OD (89mm) | 8.4 pts. (4.0L) |
| 4-Speed (117mm) | 8.4 pts. (4.0L) |
TRANSMISSION REFILL CAPACITIES
| Application | Capacity |
|---|---|
| Model 205 | 5.2 pts. (2.5L) |
| Model 207 | 10.0 pts. (4.7L) |
| Model 208 | 4.6 pts. (2.2L) |
| Model 231 | 2.2 pts. (1.1L) |
| Model 241 | 4.6 pts. (2.2L) |
TRANSFER CASE REFILL CAPACITIES
ADJUSTMENTS
Note. The 4-speed 117mm transmission has no shift rods. The shift lever mounts directly to the top of the transmission, and is therefore not adjustable.
All With Column Shifter
- Remove shift rods from transmission. Place First and Reverse gear selector lever on transmission in Reverse position. Move second and third transmission shift lever to forward detent, then back one.
- Place column shifter in Reverse position. Turn ignition switch to "LOCK" position. Move column shifter to Neutral position and put a 1/4" gauge pin through holes in shift levers at base of steering column.
- Loosen slide swivel on First and Reverse rod and place transmission shift lever in First and Reverse. Hold tightly in place and tighten swivel adjusting bolt. Install second and third shift rod.
- Unlock steering wheel and remove gauge pin. Lubricate all rod and swivel connections.
All With Floor-Mounted Shifter (Except 4-Speed 89mm)
- Disconnect all shift rods from transmission shift levers. With shift control lever in Neutral position, insert a 1/4" diameter pin through alignment holes in shifter assembly.
- Align both shift levers on the transmission in the forward detent, then back one detent. Loosen lock nuts on shift swivel ends and align rod ends with shift lever holes.
- Install shift rods in levers, tighten lock nuts and install lock pins. Remove alignment pin and check for proper linkage operation.
Floor-Mounted Shifter (4-Speed 89mm)
- Loosen all shift rod adjustment nuts at transmission shift levers. Move shift control lever to Neutral position. Move all 3 transmission shift levers into Neutral.
- Put a 1/4" gauge pin through control levers at base of shifter assembly. Hold shift rods forward tightly in their swivels and tighten adjustment nuts in that position.
- Remove gauge pin. Lubricate all swivel joints and shift control.
